Yamaha TZR250 1987 Manuals

Manuals and User Guides for Yamaha TZR250 1987. We have 1 Yamaha TZR250 1987 manual available for free PDF download: Service Manual

Yamaha TZR250 1987 Service Manual (320 pages)

Brand: Yamaha | Category: Motorcycle | Size: 52 MB

Index
2
How to Use this Manual
3
Particularly Important Information
3
Illustrated Symbols
4
Contents
5
Motorcycle-Identification
13
General Information
13
Frame Serial Number
13
Engine Serial Number
13
Preparation for Removal and Disassembly
14
All Replacement Parts
15
Lock Washers/Plates and Cotter Pins
15
Bearings and Oil Seals
15
Special Tools
16
Circlips
16
For Tune up
16
For Engine Service
17
For Chassis Service
18
For Electrical Components
18
Specifications
20
Maintenance Specifications
22
Engine
22
Electrical
31
General Torque Specifications/Definition of Units
34
Lubrication Points and Lubricant Type
35
Lubrication Diagram
37
Coolant Flow Chart
38
Cable Routing
39
Periodic Maintenance/Lubrication Intervals
43
Periodic Inspection and Adjustment
43
Cowlings Removal
45
Cowlings Installation
46
Side Covers Removal
47
Engine Y.P.V.S. Cable Adjustment
48
Adjustment Steps
49
Carburetor Synchronization
50
Checking Steps
51
Idle Speed Adjustment
53
Throttle Cable Free Play Adjustment
54
Autolube Pump Cable Adjustment
55
Coolant Level Inspection
58
Coolant Replacement
59
Cooling System Inspection
63
Front Brake Adjustment
65
Rear Brake Adjustment
65
Brake Fluid Inspection
66
Brake Pad Inspection/Brake Light Switch Adjustment
67
Drive Chain Slack Adjustment
68
Drive Chain Lubrication/Steering Head Adjustment
70
Steering Head Adjustment
71
Front Fork Oil Replacement
73
Front Fork Oil Replacement/Front Fork Adjustment
75
Rear Shock Absorber Adjustment
76
Recommended Combinations of Front Fork and Rear Shock Absorber Settings
77
Tire Inspection
78
Wheel Inspection
79
Cable Inspection and Lubrication/Lever and Pedal Lubrication/Sidestand Lubrication/Swingarm and Relay Arm Lubrication
80
Battery Inspection
81
Battery Inspection/Fuse Inspection
83
Headlight Beam Adjustment/Headlight Bulb Replacement
85
Engine Overhaul
87
Engine Removal
87
Transmission Oil
87
Coolant
87
Muffler Assembly
88
Seat
88
Fuel Tank
88
Carburetor
89
Autolube Pump Cable and Hose
89
Clutch Cable
90
Y.P.V.S. Cables
91
Radiator
91
Leads
92
Drive Chain
92
Engine Disassembly
94
Cylinder Head, Cylinders and Pistons
94
Cluth and Primary Drive Gear
96
Shift Shaft
99
C.D.I. Magneto
100
Crankcase (Upper)
101
Transmission, Shifter and Crankshaft
102
Power Valves
103
Oil Pump and Strainer
104
Inspection and Repair
105
Cylinder Head
105
Cylinder and Piston
106
Piston Rings
108
Piston Pin and Bearing
109
Clutch
110
Primary Drive
112
Transmission and Shifter
112
Kick Starter
114
Oil Pump
114
Autolube Pump
115
Crankshaft
115
Crankcase
116
Oil Pipe and Strainer
117
Power Valve
117
Engine Assembly and Adjustment
118
Oil Pump Clearance
119
Crankshaft, Piston and Piston Ring
125
Shifter
126
Transmission
127
Bolt Tightening Steps
128
Change Lever Position Adjustment Steps
132
Shift Shaft and Change Pedal
133
Kick Axle and Kick Idle Gear
135
Clutch and Primary Drive Gear
136
Cylinder Head, Cylinder and Pistons
140
Cylinder and Cylinder Head
143
Remounting Engine
144
Cooling System
149
Water Pump
149
Inspection
152
Installation
153
Thermostatic Valve and Radiator
155
Carburetion
162
Section View
163
Measurement and Adjustment Steps
170
Fuel Level Adjustment
172
Reed Valve
173
Chassis
177
Front Wheel
177
Wheel Bearing Replacement Steps
179
Rear Wheel
182
Front and Rear Brake
186
Front and Read Brake
188
Brake Pad Replacement
188
Front Brake
188
Rear Brake
190
Caliper Disassembly
192
Caliper Piston Removal Steps
193
Master Cylinder Disassembly
194
Air Bleeding
204
Front Fork
206
Removal Steps
209
Steering Head and Handlebars
215
Bearing Race Replacement Steps
219
Left-Hand Handlebar Replacement Steps
220
Ring Nut Tightening Steps
221
Rear Shock Absorber and Swingarm
225
Handling Notes
226
Notes on Disposal
226
Rear Shock Absorber
227
Swingarm
228
Drive Chain and Sprockets
234
Driven Sprocket Replacement Steps
236
Meter Assembly
239
TZR Circuit Diagram
243
Color Code
244
Electrical Components
245
Ignition and Starting System
247
Circuit Diagram
247
Ignition Control Circuit Operation
249
Troubleshooting
250
If Ignition System Should Become Inoperative (no Spark or Intermittent Spark)
250
Charging System
260
The Battery Is Not Charged
262
Lighting System
265
Headlight, Taillight or Auxiliary Light Do Not Come on
267
Lighting System Tests and Checks
271
Signal System
274
Flasher Light, Brake Light or Horn Do Not Operate
276
Signal System Tests and Checks
280
Reed Switch Test
283
Display System
284
Indicator Lights and Meter Lights Do Not Come on
286
Display System Tests and Checks
289
Oil Level Gauge Operation Check
292
When Engine Is Hot, Temperature Gauge Does Not Move
295
Thermo Unit Resistance Measurement Steps
298
Yamaha Power Valve System
299
When Main Switch Is Turned to "On", Servomotor Does Not Operate One Cycle
301
TZR250 Wiring Diagram
305
Starting Failure/Hard Starting
306
Starting Failure/Hard Starting/Poor Idle Speed Performance
308
Poor Medium and High Speed Performance
309
Faulty Gear Shifting
311
Clutch Slipping/Dragging
312
Improper Kicking
313
Faulty Brake/Front Fork Oil Leakage and Front Fork Malfunction
314
Instable Handling
315
Faulty Signal and Lighting System
316
Faulty Signal and Lighting System/Faulty Y.P.V.S.
317
Overheating or Over-Cooling
318
Handling of Asbestos Parts
319

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Yamaha TZR250 1987 Service Manual (320 pages)

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